Job Description

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Job Purpose
To support SH Process (Pre Clinkerisation) for Planning, organising and coordinating departmental budget preparation of Production and SNS &RPM, implementation of ISO standard Ensure availability of critical equipment's by timely maintenance, procurement of shut down related materials
Job Context & Major Challenges
Job Context: UltraTech Cement Ltd. is the largest manufacturer of grey cement, Ready Mix Concrete (RMC) and white cement in India. The company has consolidated capacity of 116.75 Million Tons Per Annum (MTPA)* of grey cement. UltraTech Cement has 23 integrated plants, 1 clinkerisation plant, 26 grinding units and 7 bulk terminals
Grasim Industries Limited (GIL) acquired Dharani Cements Ltd. (DCL), a 200 TPD capacity mini cement plant located in southern part of Tamil Nadu with vast mineral resources of lime stone deposits available nearby, in the year 1998 to strengthen it's position in lucrative Cement market of Tamilnadu & Kerala. Soon after acquisition , GIL started setting up of a Greenfield one million ton capacity cement plant as a separate division of GIL known as -Cement Division - South- which was commissioned in April 2000 with state of art technology & Robo (Auto) Lab, first of it's kind in India. DCL was merged with GIL in Nov 2000 to utilise mineral resources as well as manpower & other resources optimally for both the Plants & in line with consolidation taking place in Indian Cement Business. The new plant has advantage of lower power & fuel consumption & operations have stabilised in the least time. The Unit has to it's credit obtaining ISO 9001-2000 Certification in July 2001 & EMS 14001-1996 Certification in October 2001 i.e within one & half year of start of operations GIL(South) is a state of art plant with latest technology featuring an assemblaze of fuzzy logic, X-Ray analyser and CEM SCANNER operating with least a man power producing a range of premium brand of cement .The technical know- how and main equipments were obtained from Fuller, Losche & KHD.
Job Holder is responsible for proper preparation of overall Departmental budget of Production, SNS & RPM, along with ensuring implementation of ISO standards requirement and time tinme to ensure availability of critical equipment's by timely maintenance, procurement of shut down related materials
Job Challenges:
1. Operate & maintain process parameters as per Total Quality Integrated Management System for Kiln and coal mill as to ensure uninterrupted plant production
2.Carry out shutdown activies within budgeted SNS & RPM.
3. Material availability and consumption planning during shutdown.
Key Result Areas KRA (Accountabilities) (Max 1325 Characters) Supporting Actions (Max 1325 Characters)
KRA1 1) Operational Management:
Operation and optimization of Kiln/raw mill/coal mill as to achieve the targeted production and Power. o Production and SNS & RPM Bugdet planning.

• Process Studies to implement good practices
• Check out the critical requirements to ensure sustained run and work together with cross functional departments.
• Flash Production planning.
• Fuel consumption planning.
• Maintaining CCR counter record and checking of production report.
• Implementation and preparing of ISO docuements.
• Maintain manpower schedule in KRONOS.
• Putting production and SNS & RPM budget in TM1.
• Clinker and coal rate loss booking.
• Generate process Order of material
• Preparing PAT data.
• Cross Checking of Production and consumption of material.
• Automise and track kiln/rawmill/coalmill circuit to avoid idle running of equipment
• Calibration of lime stone/ china clay/ silica send, laterite and kiln feed feeders.

KRA2 2) Plant availability:
Avoid trippings ,Planning and execute Shutdown activity Kiln. o Attend and analyse stoppages and rectify the same to improve equipment availability or reduce start stop.

• Ensuring critical tools and tackles timley maintenance and availability.
• Be ready for opportunity maintenance.
• Prepare work check list, ensure availability of critical tools and with coordination of service department make shutdown bar chart for smooth work environment.
• Prepare work check list, ensure availability of critical tools and with coordination of service department make shutdown bar chart for smooth work environment.
• Ensure full empty out of coal bin, kiln and cooler before stopping the plant for shutdown and ensure 100 % safe work condition like equipment cool down, removal of hot material and preheater kiln coatings before carry out any specific job.

KRA3 2) Plant availability:
Avoid trippings ,Planning and execute Shutdown activity Kiln. o Ensuring kiln inlet and riser cleaning in all shifts as well as checking physical condition of cooler HRB. Maintaining daily record of fuel quality, raw mix quality and shell radiation temperatures if any abnormality found inform to SH/HOD as well as technical cell to take immediate control measures.

• Red Box filling, kiln inlet poking, tracking kiln shell temperature, monitoring raw mix and fuel quality parameters and managing shift manpower
• Daily Trends review and checklist execution Record day wise production and Power Consumption and prepare comparative data for study/analysis.

KRA4 3) Process Maintenance Jobs Pyro
Implementation of various process
maintenance jobs in coordination with other maintenance department to improve equipment availability o Material planning for shutdown

• Physical inspection of received material in store.
• Ensuring Sufficient manpower availability for shut down by conducting all gate pass process.
• Physical Inspection castable and refractory condition.
• Ensuring sufficient material shifting from store to site.
• All process equipment maintenance and calibiration.
• Raising PR for refractory, castable, general items, spare parts for brokk, UT pump, mixer machine, belt conveyor and brick lining machine.
• Supply Bill posting in SAP.
• VRM (Coal Mill) internal inspection, separator inspection, water flow check, any material accumulation, hot gas chamber, damper calibration, roller position calibration.
• Ensure false air point to be arrested during shut down
• If found any abnormality inform concer department for corrective actions.

KRA5 4)Cost Control:
Optimized run of Kiln and coal mill. o Achieve targeted power consumption and throughput of kiln and coal mill.

• Refractory management
• Timely completion of kiln shut down activity.
• Reduction in Stores & spares cost.
• Ensure proper hous keeping by zero spillage points to reduce RPM.
• Monitoring of power consumption and specific heat consumption and take corrective action to reduce the same.

KRA6 5)SHE (Safety, Health & Environment) along with Sustainability initiatives o Ensuring 100% compliance of all safety standards and all applicable recommendations related to their concerned area.

• Educating team about "I know my job", "I know the hazards associated with my job and I applied control measures" & "I escalate to my senior" among manpower deployed in sections/department manpower including peer, WB & CL manpower
• Timely conducting scheduled SO round and reporting of accidents, incidents and near misses on occurrences in the area of concern in system.
• To conduct daily Tool Box Talk as schedule and before start the job any critical job along with SWP
• Active participation in safety training, safety sub committees, standard champions meeting and any safety event
• Ensure good housekeeping, limited use of power, no leakage of water, oil, air etc and reporting concerned if any abnormalities for corrective action
• Adhering of all safety precautions on the site and off the site
• Replicating good practice for saving environment for long run sustainability and creating awareness among manpower to save guard natural resources.

KRA7 6)System Management
(Effective implementation of all IMS and other systems requirements through involvement for continuous improvement in plant working condition & quality standards) o To implement improvement project to reduce repetitive problems/breakdown or losses.

• Timely submission of Kaizen, OPL, Good to fine, suggestion on system
• Developing and sustaining Model area in respective sections
• 100% active participation in respective KFA & GRT meetings and giving inputs related to bring new technology, innovation and improvements towards productivity. Conduct awareness programmes down the level team
• To know about IMS and other systems requirement and documents for Non-Conformity in section during internal and external audits or assessments.
• Implementation of critical spares & consumable SOP without any defilement
• Identify & arrange rectification of leakage points/unsafe points along with monitor & take corrective action for emission levels.